1. Use a good quality hole saw like Rigid available at HomeDepo with a mandrel.
2. After making your initial pilot hole with the mandrel cut halfway through the acrylic on one side, then reverse the cut from the other side until the cut is complete. This helps prevent the acrylic from splintering.
3. Go slow and staight with your drill allowing the tool to do the work vs pressing hard on the drill.
4. Finish off the hole with a fine tooth round file or some 150 grit sandpaper to smooth the edges.
5. Like an oil filter - tighten the fittings hand tight and then give it a good 1/2 rotation turn with a wrench.
Tip: I strongly recommend using a high quality clear silicon sealant on both sides of the bulkhead. It essentially assures a water tight seal for life. Let it dry before you work with the part again. If you are attaching a threaded fitting it is best to use Teflon pipe sealant to the threads and affix that part to the bulkhead before mounting the bulkhead to the sump. Once the silicon has dried you want to disturb the bulkhead as little as possible.
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